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Representative illustration: A controls systems integrator and OEM was behind schedule in both divisions, with lost parts and labor overruns driving costs.

Case Study · Aerospace & Manufacturing

A controls systems integrator and OEM was behind schedule in both divisions, with lost parts and labor overruns driving costs.

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1Challenge

Orders sold beyond capacity overwhelmed a spreadsheet-run warehouse; parts were lost and reordered, work started without full kits, and there was little data or MOS.

2Approach

  • Regained warehouse control with control logs and leader standard work, then a barcode Warehouse Management System
  • Converted batch production to single piece flow with takt time, balanced stations and only 100% kits
  • Built a full MOS with employee-led kaizen, kanban and poka-yoke

3Results

99%

Year-over-year throughput improvement

51%

Lower monthly labor cost per job order

80%

Better inventory accuracy

$1.5M

Increase in annual revenue

Plus $500K in cost avoidance from being able to find parts.

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© USC Consulting Group 2026 | Aerospace & Manufacturing. Representative industry image. Results are engagement-specific; sizing and forecast figures are labeled as such.